Ceramic composite

• US 9,376,552 B2
• Filed: 08/29/2014
• Issued: 06/28/2016
• Est. Priority Date: 04/29/2009
• Status: Active Grant

• Current Assignee: Tundra Composites, LLC.
• Original Assignee: Tundra Composites, LLC.
• Inventors: Heikkila, Kurt E., Williams, Rodney K., Kroll, John S.
• Primary Examiner(s): CAIN, EDWARD J
• Application Number:
  US14/473,675
• Publication Number:
  US 20150057402A1
• Time in Patent Office: 669 Days
• Field of Search: 523/220, 524/444
• US Class Current: 1/1
• CPC Class Codes: B60C 1/00 Tyres characterised by the chemical composition or the physical arrangement or mixture of the composition
• CPC Class Codes: C08J 2327/16 Homopolymers or copolymers of vinylidene fluoride
• CPC Class Codes: C08J 2327/18 Homopolymers or copolymers of tetrafluoroethylene
• CPC Class Codes: C08J 2327/20 Homopolymers or copolymers of hexafluoropropene
• CPC Class Codes: C08J 5/04 Reinforcing macromolecular compounds with loose or coherent fibrous material
• CPC Class Codes: C08K 2003/2227 of aluminium
• CPC Class Codes: C08K 2201/005 Additives being defined by their particle size in general
• CPC Class Codes: C08K 3/22 of metals
• CPC Class Codes: C08K 7/28 Glass
• CPC Class Codes: C08K 9/00 Use of pretreated ingredients
• CPC Class Codes: C08K 9/04 Ingredients treated with organic substances treated with macromolecular compounds C08K9/08
• CPC Class Codes: C08L 21/00 Compositions of unspecified rubbers
• CPC Class Codes: Y10T 428/249974 Metal- or silicon-containing element

Abstract

The invention relates to a ceramic particulate and polymer composite having enhanced viscoelastic and rheological properties.

Claims

1. A thermoplastic composite with improved viscoelastic properties comprising a shaped article comprising a melt blended ceramic particle in a polymer phase, the composite comprising:

(a) a ceramic particle, having a density greater than 0.10 gm-cm<sup>−

3</sup> and less than 10 gm-cm<sup>−

3</sup>; and

(b) about 13 to 51 vol. % of a thermoplastic polymer phase;

wherein the ceramic particulate comprises a particle size P_s of about 10 to 500 microns and the composite comprises a second particulate with a second particle size P_s¹ that differs from P_s by at least 5 microns, the particulate has an exterior coating comprising about 0.005 to 3 wt.-% of an interfacial modifier, based on the composite; and

the composite density is about 0.9 to 10 gm-cm<sup>−

3</sup>;

wherein the thermoplastic composite is free of a polymer consisting of tetrafluoroethylene, the ceramic particulate having a circularity greater than 12.5 and an aspect ratio less than 1;

9.

2. The thermoplastic composite of claim 1 wherein the polymer comprises a polyamide.

3. The thermoplastic composite of claim 1 wherein the polymer comprises a nylon.

4. The thermoplastic composite of claim 1 wherein the polymer comprises a poly(ethylene-co-vinyl acetate).

5. The thermoplastic composite of claim 1 wherein the polymer comprises a polyvinyl chloride.

6. The thermoplastic composite of claim 1 wherein the polymer comprises a thermoplastic fluoropolymer.

7. The thermoplastic composite of claim 1 wherein the polymer comprises a polyolefin.

8. The thermoplastic composite of claim 1 wherein the polymer comprises a thermoset polymer.

9. The thermoplastic composite of claim 1 wherein the polymer comprises a high-density polyolefin.

10. The thermoplastic composite of claim 1 wherein the particulate comprises a coating comprising about 0.01 to 4 wt % of an interfacial modifier based on the composite.

11. The thermoplastic composite of claim 1 wherein the particle has an excluded volume of about 13 vol.-% to about 70 vol.-%.

12. The thermoplastic composite of claim 1 wherein the particle has an excluded volume of about 13 vol.-% to about 60 vol.-%.

13. The thermoplastic composite of claim 1 wherein the polymer comprises a thermoplastic fluoroelastomer.

14. The shaped article of claim 1 wherein the article is a transportation bumper, a commercial or residential weather strip, an abrasive layer, a vapor resistant hose, a transportation interior panel, a sealant for a fenestration unit or installation, a structural member for a sound box, a transportation brake pad, engine or drive train counterweight, automotive or truck wheel weight, an LED heat dissipation fixture, a refrigeration unit thermal seal, or a fenestration composition.

15. The shaped article of claim 1 wherein the composite material can be formed into objects using conventional thermoplastic polymer forming techniques.

16. The shaped article of claim 15 wherein the thermoplastic forming techniques comprises extrusion, injection molding, or compression molding.